Vacuum insulated panel for counteracting vacuum bow induced deformations

ABSTRACT

A vacuum insulated cabinet structure includes first and second cover members having pre-deformed portions and perimeter portions. The perimeter portions of the first and second cover members are disposed along first and second planar levels and the pre-deformed portions of the first and second cover members include portions thereof extending outwardly relative to the first and second planar levels. A thermal bridge interconnects the first cover member and the second cover member at the perimeter portions thereof to define an insulating cavity therebetween. The insulating cavity is a sealed cavity having a vacuum drawn therefrom. The pre-deformed portions of the first and second cover members move inwardly towards the first and second planar levels under a force of the vacuum within the insulating cavity.

BACKGROUND

The present device generally relates to insulated structures, and inparticular, to vacuum insulated refrigerator cabinets that includevacuum cavities disposed between an exterior wrapper and a liner.

Various types of insulated refrigerator cabinet structures have beendeveloped. One type of insulated cabinet structure includes an exteriorwrapper and a liner. The wrapper and liner are generally spaced-apart toform an internal cavity. The cavity is generally filled with aninsulating material or a polyurethane foam. In vacuum insulated cabinetstructures, the cavity formed between a wrapper and a liner may includea vacuum and an insulating material to form a vacuum insulatedstructure. Sidewalls of the liner and exterior wrapper are often subjectto deformation when drawing a vacuum on the vacuum cavity due to thevacuum pressures involved in such a process. Vacuum insulated structureshaving repeatable and consistent outer parameters are desired for aclean aesthetic of the wrapper and the liner in a vacuum insulatedrefrigerator structure.

SUMMARY

One aspect of the present concept includes a vacuum insulated structurehaving a first cover member having a pre-deformed portion and aperimeter portion. The perimeter portion of the first cover member isdisposed along a first planar level and the pre-deformed portion of thefirst cover member includes portions thereof extending outwardlyrelative to the first planar level. A second cover member includes apre-deformed portion and a perimeter portion. The perimeter portion ofthe second cover member is disposed along a second planar level and thepre-deformed portion of the second cover member includes portionsthereof extending outwardly from the second planar level. A thermalbridge interconnects the first cover member and the second cover memberat the perimeter portions thereof to define an insulating cavitytherebetween. The insulating cavity is a sealed cavity having a vacuumdrawn therefrom. The pre-deformed portions of the first and second covermembers move inwardly towards the first and second planar levels under aforce of the vacuum within the insulating cavity.

Another aspect of the present concept includes a method of making avacuum insulated cabinet structure. The method includes the steps of: 1)providing an exterior wrapper having a receiving cavity defined by aplurality of sidewalls; 2) outwardly deforming one or more of thesidewalls of the exterior wrapper, such that the sidewalls of theexterior wrapper include pre-deformations outwardly extending beyond afirst desired planar level; 3) providing at least one liner having aplurality of sidewalls defining a compartment; 4) outwardly deformingone or more of the sidewalls of the at least one liner, such that thesidewalls of the at least one liner include pre-deformations outwardlyextending beyond a second desired planar level; 5) positioning the leastone liner in the receiving cavity of the exterior wrapper; 6) providinga thermal bridge interconnecting the exterior wrapper and the at leastone liner to define an insulating cavity therebetween having a firstinterior volume; 7) drawing a vacuum on the insulating cavity; 8)collapsing the pre-deformations of the sidewalls of the exterior wrapperto draw the sidewalls of the exterior wrapper into alignment with thefirst desired planar level; collapsing the pre-deformations of thesidewalls of the at least one liner to draw the sidewalls of the atleast one liner into alignment with the second desired planar level; and9) decreasing the first interior volume of the insulating cavity to asecond interior volume.

Another aspect of the present concept includes a method of making avacuum insulated structure. The method includes the steps of: 1)providing first and second cover members; 2) pre-deforming the first andsecond cover members to form pre-deformed portions on each of the firstand second cover members, wherein the pre-deformed portion of the firstcover member extends outwardly from a first planar level of the firstcover member, and further wherein the pre-deformed portion of the secondcover member extends outwardly from a second planar level of the secondcover member; 3) operably coupling the first and second cover members toone another to form an insulating cavity therebetween; 4) introducing aninsulation material into the insulating cavity; 5) drawing a vacuum onthe insulating cavity; 6) drawing the pre-deformed portions of the firstand second cover members inwardly towards the first and second planarlevels of the first and second cover members, respectively, under aforce provided by the vacuum; and 7) sealing the insulating cavity tomaintain the vacuum.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1A is a isometric view of a refrigerator including a vacuuminsulated cabinet structure;

FIG. 1B is an exploded perspective view of another vacuum insulatedcabinet structure;

FIG. 2A is a top perspective view of a sidewall of a vacuum insulatedcabinet structure prior to a vacuum drawing procedure;

FIG. 2B is a top perspective view of the sidewall of the vacuuminsulated cabinet structure of FIG. 2A after a vacuum has been drawn;

FIG. 3A is a cross-sectional view of the sidewall of the vacuuminsulated cabinet structure of FIG. 2A taken at line IIIA;

FIG. 3B is a cross-sectional view of the sidewall of the vacuuminsulated cabinet structure of FIG. 2B taken at line IIIB;

FIG. 4 is a an exploded top perspective view of a sidewall of a vacuuminsulated cabinet structure according to an embodiment of the presentconcept;

FIG. 5A is a top perspective view of the sidewall of the vacuuminsulated cabinet structure of FIG. 4 in an assembled condition andprior to a vacuum being drawn;

FIG. 5B is a top perspective view of the sidewall of the vacuuminsulated cabinet structure of FIG. 5A after a vacuum has been drawn;

FIG. 6 is a cross-sectional view of the sidewall of the vacuum insulatedcabinet structure of FIG. 5A taken at line XI.

FIG. 7 is a cross-sectional view of the sidewall of the vacuum insulatedcabinet structure of FIG. 5B taken at line XII;

FIG. 8 is an exploded top perspective view of a sidewall of a vacuuminsulated cabinet structure according to another embodiment of thepresent concept;

FIG. 9A is a cross-sectional view of the sidewall of the vacuuminsulated cabinet structure of FIG. 8 in an assembled condition;

FIG. 9B is a cross-sectional view of the sidewall of the vacuuminsulated cabinet structure of FIG. 9A, after a vacuum has been drawn;

FIG. 10A is a cross-sectional view of a vacuum insulated structureaccording to another embodiment having pre-deformed sidewalls;

FIG. 10B is a cross-sectional view of the vacuum insulated structure ofFIG. 10A after a vacuum has been drawn on the structure;

FIG. 11A is a cross-sectional view of a vacuum insulated structureaccording to another embodiment having internal chamber structuresdisposed within the sidewalls; and

FIG. 11B is a cross-sectional view of the vacuum insulated structure ofFIG. 11A after a vacuum has been drawn on the structure.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 5A. However, itis to be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

Referring now to FIG. 1A, a refrigerator 10 is shown having a vacuuminsulated cabinet structure 12. The vacuum insulated cabinet structure12 includes one or more front openings 14A, 14B that may be closed offby doors 16A, 16B and 16C. The doors 16A, 16B are contemplated to pivotbetween open and closed positions relative to upper front opening 14A.As further found in the illustrated example, door 16C is in the form ofa sliding drawer which horizontally slides between open and closedpositions for selectively providing access to the lower front opening14B of the insulated cabinet structure 12.

As further shown in FIG. 1A, the vacuum insulated cabinet structure 12includes an exterior wrapper 18 and upper and lower liners 20A, 20B. Inthe embodiment shown in FIG. 1A, the upper and lower liners 20A, 20Bgenerally indicate a refrigerator compartment and a freezer compartment,respectively. In assembly, the upper and lower liners 20A, 20B areinterconnected with the exterior wrapper 18 via a thermal bridge 22. Thethermal bridge 22 is best shown in FIG. 1B. As further shown in FIG. 1A,the exterior wrapper 18 is spaced-apart from the upper and lower liners20A, 20B to define an insulating cavity 24 therebetween. The insulatingcavity 24 is contemplated to be a sealed cavity that may comprise avacuum core material such as a silica powder or other suitable loosefiller material that is inserted (e.g., blown) into the insulatingcavity 24 after the exterior wrapper 18, upper and lower liners 20A, 20Band thermal bridge 22 have been coupled together.

Referring now to FIG. 1B, the vacuum insulated cabinet structure 12 isshown in an exploded view. The thermal bridge 22 of the vacuum insulatedcabinet structure 12 includes first and second side members 22A and 22Balong with upper and lower openings 25, 26 which are configured to alignwith the upper and lower liners 20A, 20B in assembly. The thermal bridge22 further includes a mullion portion 28 disposed between the upper andlower openings 25, 26 and extending between the first and second sidemembers 22A, 22B. The upper liner 20A is shown having a top wall 30, abottom wall 32, opposed side walls 34, 36 and a rear wall 38(collectively referred to herein as sidewalls) which all cooperate todefine a refrigerator compartment 40. Similarly, the lower liner 20Bincludes a top wall 42, a bottom wall 44, interconnecting sidewalls 46,48 and a rear wall 49 which all cooperate to define a freezercompartment 50. The rear wall 49 is shown having a stepped configurationto define a spacing 52 which may be used to house various coolingcomponents for cooling both the refrigerator compartment 40 and thefreezer compartment 50. The upper and lower liners 20A, 20B may becomprised of a sheet metal material that is folded and welded to definethe parameters of the refrigerator compartment 40 and the freezercompartment 50.

As further shown in FIG. 1B, the exterior wrapper 18 includes a top wall54, a bottom wall 56, opposed sidewalls 58, 60 and a rear wall 62(collectively referred to herein as sidewalls) which together cooperateto define a receiving cavity 64. The exterior wrapper 18 may becomprised of a sheet metal material that is folded and/or welded todefine the parameters of the receiving cavity 64. In assembly, the upperand lower liners 20A, 20B are received in the receiving cavity 64 of theexterior wrapper 18, such that the exterior surfaces of the upper andlower liners 20A, 20B cooperate with the inner surfaces of the exteriorwrapper 18 to define the insulating cavity 24 disposed therebetween asshown in FIG. 1A. In the embodiment shown in FIG. 1B, a plurality ofvacuum insulated panels 70A-70E are shown configured for insertion intothe insulating cavity 24 between the upper and lower liners 20A, 20B andthe exterior wrapper 18. The vacuum insulated panels 70A-70E shown inFIG. 1B may include several different configurations of panels used tofill the insulating cavity 24 without departing from the spirit of thepresent concept. The panels 70A-70E are contemplated to be vacuuminsulated panels having a vacuum drawn therefrom to provide superiorinsulating capabilities as used in the vacuum insulated cabinetstructure 12. Polyurethane foam may also be used in the insulationsystem to provide additional insulation as well as assist in holding thepanels 70A-70E in place within the insulating cavity 24. Further, it iscontemplated that the insulating cavity 24 may directly receive aninsulating material and have a vacuum drawn directly from the insulatingcavity 24 to provide a vacuum insulating cabinet structure 12. In thisway, the vacuum insulated cabinet structure 12 may include an overallthinner profile to maximize the amount of space available for therefrigerator compartment 40 and the freezer compartment 50 in assembly.

Referring now to FIG. 2A, a vacuum insulated panel 70 is used todescribe a deformation effect of a vacuum drawing procedure. The vacuuminsulated panel 70 includes upper and lower cover members 72, 74 whichare spaced-apart from one another and interconnected by side members75-78. The side members 75-78 may be side members of a unitary framestructure to which the upper and lower cover members 72, 74 areattached. In assembly, the vacuum insulated panel 70 includes a cavity80 defined by the upper and lower cover members 72, 74 as spaced-apartfrom one another and interconnected by side members 75-78. The cavity 80may be filled with a particulate material, such as a compressed cake ofactivated carbon black or silica gel, or a mixture of the two. Thesefillers are designed to fill the cavity 80 and are placed therein beforea vacuum is drawn on the panel 70. The filler is indicated by referencenumeral 82 and is best shown in FIG. 3A.

Referring now to FIG. 2B, the vacuum insulated panel 70 has had a vacuumdrawn on the cavity 80, such that the cavity 80 now defines an evacuatedcavity 80. By drawing the vacuum on the vacuum insulated panel 70, theupper and lower cover members 72, 74 have inwardly collapsed towardseach other, thereby providing for a deformed outer surface 72A of uppercover member 72 as shown in FIG. 2B. The deformation of the vacuuminsulated panel 70 shown in FIG. 2B is best depicted in FIG. 3B.

Referring now to FIG. 3A, the cross-sectional view of the vacuuminsulated panel 70 shown in FIG. 2A is depicted, wherein the outersurface 72A of upper cover member 72 and an outer surface 74A of thelower cover member 74 are shown in substantially planar configurationsbetween side members 78, 76. This configuration shown in FIG. 3A is anideal configuration for a vacuum insulated panel after a vacuum has beendrawn on the panel. However, as noted above, when a vacuum is drawn onthe vacuum insulated panel 70 of FIGS. 2A and 3A, a deformed vacuuminsulated panel 70, as shown in FIGS. 2B and 3B, is often the result.With specific reference to FIG. 3B, the outer surfaces 72A, 74A of theupper and lower cover members 72, 74 are no longer planar outersurfaces, but rather inwardly deformed outer surfaces having specificindent deformations 84A-84D which draw the upper and lower cover members72, 74 towards one another due to the low pressure of the evacuatedcavity 80. The pressure within the evacuated cavity of panel 70 iscontemplated to be less than 10 mbar as compared to an atmosphericpressure of 1 atm or 1013.25 mbar.

In an effort to avoid the vacuum deformation bow shown in the vacuuminsulated panel 70 of FIGS. 2A-3B, the present concept includes a vacuuminsulated structure having pre-deformations, as further described below.Specifically, in the embodiment shown in FIGS. 4-7, a simplified versionof a vacuum insulated structure 90 is shown, wherein it is contemplatedthat the vacuum insulated structure 90 may include a standalone vacuuminsulated panel. Further, the vacuum insulated structure 90 is alsoconfigured to represent a pre-deformation technique as applied to anentire vacuum insulated structure, such as the vacuum insulated cabinetstructure 12 of FIG. 1A at the insulating cavity 24. As such, it iscontemplated that the vacuum insulated structure 90 illustrates anexemplary structure having a pre-deformation technique used to provide asubstantially planar structure after a vacuum has been drawn therefrom.The configuration of the vacuum insulated structure 90 is not meant tolimit the scope of the present concept in any manner. Further, as shownin FIGS. 10A and 10B, the pre-deformation technique may apply to avacuum insulated structure 90B which specifically relates to thestructure of a refrigerator cabinet. Thus, the vacuum insulatedstructure 90 shown in FIGS. 2A-3B may represent a single sidewall of avacuum insulated cabinet structure 90B shown in FIGS. 10A and 10B.

Thus, in accordance with the present concept, a vacuum insulatedstructure 90 is shown in FIG. 4 in an exploded view having an uppercover member 92 and a lower cover member 94 which are spaced-apart fromone another and configured to couple to a thermal bridge 96 having sidemembers 96A-96D. An evacuation port 98 is shown disposed on the thermalbridge 96, but may be disposed on any part of the vacuum insulatedstructure 90 for accessing a cavity 100 (FIG. 5A). As shown in FIG. 4,the upper and lower cover members 92, 94 may include walls of theexterior wrapper 18 and the upper and lower liners 20A, 20B which arealso spaced-apart from one another to define an insulating cavity 24disposed therebetween as shown in FIG. 1A As referenced herein, theupper and lower cover members 92, 94 are described as “upper” and“lower” cover members for purposes of description only and do not definea specific configuration for the vacuum insulated structure 90. Theupper and lower cover members 92, 94 define first and second covermembers which are spaced-apart in assembly of the vacuum insulatedstructure 90, and may be disposed in any relationship to one anotherbesides the vertical relationship shown in FIGS. 4-7. The upper covermember 92 includes an outer surface 92A having a pre-deformed portion92B disposed in a generally central portion of the cover member 92.Similarly, the lower cover member 94 includes an outer surface 94Ahaving a pre-deformed portion 94B disposed in a generally centralportion of the cover member 94. The pre-deformed portions 92B, 94B ofthe upper and lower cover members 92, 94 outwardly extend from a desiredplanar level position as further described below with specific referenceto FIG. 6. The upper and lower cover members 92, 94 include perimeterportions 92C, 94C, respectively, which surround the pre-deformedportions 92B, 94B. The perimeter portions 92C, 94C are generallydisposed at the desired planar level, as further described below.

The upper and lower cover members 92, 94 are contemplated to be sheetmetal cover members, wherein the pre-deformed portions 92B, 94B arestamped portions formed by a stamping process which stretches and thinsspecific portions around the pre-deformed portions 92B, 94B. Withspecific reference to upper cover member 92, weakened portions 93A-93Dare shown disposed around pre-deformed portion 92B and are contemplatedto be weakened portions of the cover member 92 having been stretched andthinned during a stamping process. Similarly, pre-deformed portion 94Bof lower cover member 94 includes weakened portions 95A-95D which arethinned or weakened portions due to a stamping process that provides forthe outwardly extending configuration of pre-deformed portion 94B. Inassembly, the upper cover member 92 couples to a first surface 97 ofthermal bridge 96, while lower cover member 94 couples to a secondsurface 99 of the thermal bridge 96. By coupling the upper cover member92 and the lower cover member 94 to the thermal bridge 96, a cavity forthe vacuum insulated structure 90 is formed. The cavity is identified asreference numeral 100 as shown in FIGS. 5A, 5B, 6 and 7 and iscontemplated to represent a portion of insulating cavity 24 of vacuuminsulated cabinet structure 12 shown in FIG. 1A.

Referring now to FIG. 5A, the vacuum insulated structure 90 is shown inan assembled condition as compared to the exploded view shown in FIG. 4.While the vacuum insulated structure 90 shown in FIG. 5A is provided inan at-rest or pre-evacuation stage, the structure 90 is still referredto herein as a vacuum insulated structure. In the assembled condition,the vacuum insulated structure 90 is shown having the upper and lowercover members 92, 94 coupled to the first and second surfaces 97, 99(FIG. 4) of the thermal bridge 96. In this configuration, thepre-deformed portions 92B and 94B (FIG. 4) outwardly extend from adesired planar level configuration as raised by inclined weakenedportions 93A-93D and 95A-95D, respectively. In the assembled conditionshown in FIG. 5A, the vacuum insulated structure 90 includes a cavity100 which is generally accessible via port 98 disposed in the thermalbridge 96. While the embodiment shown in FIG. 5A includes the port 98disposed on the thermal bridge 96, it is contemplated that the port 98can be disposed on any portion of the vacuum insulated structure 90, solong as the port provides access to the cavity 100. In assembling thevacuum insulated structure 90, the cavity 100 can be filled with aninsulation medium, such as open celled foam or a microporous fillermaterial which may optionally include particulate reflectors oropacifiers, such as aluminum, flake or carbon black, to reducetransmission of radiation energy through the vacuum insulated structure90. The cavity 100 may also be filled with an insulating material in theform of a powder comprised of fumed silica, glass beads, processed ricehusks, or any combination thereof. The insulating material iscontemplated to have a conducting coefficient or thermal conductivity ofat least 5 mW/m·K, or lower, to ensure that the insulating properties ofthe vacuum insulated structure 90 are sound. This filler material orinsulating material is identified in FIGS. 6 and 7 as reference numeral102.

With reference to FIG. 5B, the vacuum insulated structure 90 is shown inan evacuated condition, wherein the cavity 100 has been accessed viaport 98 to draw a vacuum from the cavity 100, thereby providing a lowpressure environment within the cavity 100. The low pressure environmentof the cavity 100 may include a reduced internal pressure of less than10 mbar, but may include other pressure settings conditioned on a fillermaterial used in the vacuum insulated structure 90, and also conditionedon the desired insulative value of the vacuum insulated structure 90. InFIG. 5B, the outer surface 92A of upper cover member 92 is shown to be agenerally planar surface, wherein the pre-deformed portion 92B (FIG. 5A)has been pulled inwardly by the drawing of the vacuum on the vacuuminsulated structure 90 to provide the substantially planar outer surface92A of upper cover member 92. This reforming of the upper cover member92 is also experienced on the lower cover member 94 at pre-deformedportion 94B, as further described below with reference to FIGS. 6 and 7.

Referring now to FIG. 6, a cross-sectional view of the vacuum insulatedstructure 90 of FIG. 5A is shown, wherein the pre-deformed portions 92B,94B of the upper and lower cover members 92, 94 are shown extendingoutwardly from desired planar levels DPL1, DPL2, respectively. As notedabove, this is generally due to the upper and lower cover members 92, 94being subject to a stamping or forming process that pre-deforms theupper and lower cover members 92, 94 to provide outwardly extendingweakened portions identified as inclined weakened portions 93A, 93C, 95Aand 95C in the upper and lower cover members 92, 94 in FIG. 6. Theperimeter portions 92C, 94C of the upper and lower cover members 92, 94are shown disposed generally at the desired planar levels DPL1, DPL2,respectively. As a vacuum is drawn on the cavity 100 of the vacuuminsulated structure 90, the upper and lower cover members 92, 94 aresubject to inwardly directed forces F1, F2, respectively, which drivethe upper and lower cover members 92, 94 towards one another. Due to theweakened condition of the weakened portions 93A, 93C, 95A, 95C, theseportions of the upper and lower cover members 92, 94 are moresusceptible to repositioning or collapsing as compared to the otherportions of the upper and lower cover members 92, 94. Thus, due to theinwardly directed forces F1, F2 caused by the vacuum drawn within thecavity 100, the pre-deformed portions 92B, 94B of the upper and lowercover members 92, 94 are drawn inwardly toward the desired planar levelsDPL1, DPL2 on the upper and lower sides of the vacuum insulatedstructure 90.

With reference to FIG. 7, the vacuum insulated structure 90 is shownafter an evacuation procedure has been preformed, such that the cavity100 now represents an evacuated cavity. The pre-deformed portions 92B,94B of FIG. 6 are no longer present in the vacuum insulated structure 90of FIG. 7, as these portions have been drawn inwardly to the desiredplanar levels DPL1, DPL2 due to the internal forces F1, F2 acting on thepre-deformed portions 92B, 94B during the evacuation procedure. Thus,the resulting vacuum insulated structure 90 shown in FIG. 7 includesouter surfaces 92A, 94A of the upper and lower cover members 92, 94having substantially planar configurations that are substantially inline with the desired planar levels DPL1, DPL2.

Referring now to FIG. 8, a vacuum insulated structure 90A is shownaccording to another embodiment of the present concept. The vacuuminsulated structure 90A includes many features similar to the vacuuminsulated structure 90 shown in FIG. 4, for which like referencenumerals will be used to represent similar features. The vacuuminsulated structure 90A is also contemplated to represent a portion ofthe vacuum insulated cabinet structure 12 shown in FIG. 1A.Representation of the concept described in FIGS. 8-9B is also shown inFIGS. 11A and 11B with particular reference to a vacuum insulatedcabinet structure 90C. As shown in the exploded view of FIG. 8, thevacuum insulated structure 90A includes upper and lower cover members92, 94 having outer surfaces 92A, 94A, respectively. The thermal bridge96 includes side members 96A-96D, as well as evacuation port 98 foraccessing a cavity 100 (FIG. 7) formed when the upper and lower covermember 92, 94 are coupled to the thermal bridge 96 at first and secondsurfaces 97, 99 of the thermal bridge 96. As further shown in FIG. 8,the vacuum insulated structure 90A includes an internal chamberstructure 110 which is generally comprised of first and second panels112, 114. The panels 112, 114 are generally mirror images of each otherand are configured to be joined together and positioned within thecavity 100 of the vacuum insulated structure 90A in assembly. The firstpanel 112 includes an outwardly extending middle portion 116 surroundedby a generally planar perimeter portion 118. Similarly, the second panel114 includes an outwardly extending middle portion 120 which issurrounded by a generally planar perimeter portion 122. It is furthercontemplated that the first and second panels 112, 114 may besubstantially planar. In assembly, as best shown in FIG. 9A, theperimeter portions 118, 122 of the first and second panels 112, 114 arejoined together in a sealable manner, such as by welding, crimping orotherwise adhering the first panel 112 to the second panel 114. In thevacuum insulated structure 90A, it is contemplated that the upper andlower cover members 92, 94 are comprised of a sheet metal material thatis generally stronger than a sheet metal material used to form the firstand second panels 112, 114. In this way, the internal chamber structure110 is more susceptible to deformation being comprised of the first andsecond panels 112, 114 which include a deformability factor that isgreater than a deformability factor of the upper and lower cover members92, 94. As used herein, the term “deformability factor” is used todescribe the ability or inability of a material to deform underparticular conditions, such as under pressures exerted on the materialduring a chamber evacuation process. Thus, as further described below,the first and second panels 112, 114 are more susceptible to deformationhaving a higher deformability factor as compared to the upper and lowercover members 92, 94 having a lower deformability factor. Thus, whendrawing a vacuum on the cavity 100 of the vacuum insulated structure90A, the first and second panels 112, 114 of the internal chamberstructure 110 are more likely to deform as compared to the upper andlower cover members 92, 94.

Referring now to FIG. 9A, the vacuum insulated structure 90A of FIG. 8is shown in an assembled condition with the internal chamber structure110 positioned within the cavity 100 of the vacuum insulated structure90A. In the assembled condition, the perimeter portions 118, 122 of thefirst and second panels 112, 114 are joined together to define aninterior cavity 124 of the internal chamber structure 110 at theoutwardly extending portions 116, 120 of the first and second panels112, 114. The interior cavity 124 is shown in FIG. 9A having a volume V1which is an at-rest volume V1 generally defined by the inner surfaces ofthe first and second panels 112, 114 pre-vacuum. It is furthercontemplated that the at-rest volume V1 of the first and second panels112, 114 may be a value of zero when the middle portions 116, 120 do notoutwardly extend as is the case with planar first and second panels 112,114. The middle portions 116, 120 of the first and second panels 112,114 may in fact be in contact with one another, however, they are notjoined to each other in a manner in which the parameter portions 118,122 of the first and second panels 112, 114 are joined. In theembodiment shown in FIG. 9A, a vacuum has not been drawn on the vacuuminsulated structure 90A, wherein the cavity 100 of the vacuum insulatedstructure 90A is accessed via port 98 (FIG. 8) for evacuating the cavity100. During the evacuation of cavity 100, the internal pressure of thecavity 100 is contemplated to drop to a low pressure setting ofapproximately less than 10 mbar. When drawing this vacuum, forces F1, F2will act on the inner surfaces 93, 95 of the upper and lower covermembers 92, 94 in an inward direction towards one another as indicatedin FIG. 9A. In the at-rest state (pre-vacuum) shown in FIG. 9A, theupper and lower cover members 92, 94 are substantially in-line with thedesired planar levels DPL1, DPL2, respectively, to provide a cleanaesthetic for the vacuum insulated structure 90A. As such, during thedrawing of the cavity 100, any deformation or repositioning of the upperand lower cover members 92, 94 is undesirable.

As noted above, the first and second panels 112, 114 of the internalchamber structure 110 have a deformability factor that is greater thanthe deformability factor of the upper and lower cover members 92, 94.When a vacuum is drawn on the cavity 100 of the vacuum insulatedstructure 90A, outwardly directed forces F3, F4 will act on the firstand second panels 112, 114 in an outward direction as indicated in FIG.9A. With the first and second panels 112, 114 being more susceptible todeformation as compared to the upper and lower cover members 92, 94, theinternal chamber structure 110 is configured to outwardly deform in acontrolled manner as the vacuum is drawn on cavity 100. By deforming theinternal chamber structure 110, the upper and lower cover members 92, 94can resist deformation and remain within the parameters of the desiredplanar levels DPL1, DPL2 to retain the shape of the vacuum insulatedstructure 90A. The interior cavity 124 is a sealed cavity, such that theinternal chamber structure 110 will deform and the slightly positivepressure of cavity 100 under vacuum will not be lost.

Thus, referring now to FIG. 9B, the vacuum insulated structure 90A isshown after a vacuum or evacuation procedure has been performed. Theupper and lower cover members 92, 94 are shown positioned in asubstantially identical configuration along desired planar levels DPL1,DPL2 as found in FIG. 9A. Thus, an interior volume V3 of the cavity 100is unchanged from FIG. 9A to FIG. 9B. The internal chamber structure 110has deformed due to the higher deformability factor of first and secondpanels 112, 114 as compared to upper and lower cover members 92, 94. Thedeformation of the internal chamber structure 110 provides for anincreased volume V2 of the interior cavity 124 as compared to theat-rest volume V1 of the interior cavity 124 shown in FIG. 9A. Thus, thedrawing of the vacuum on the cavity 100 has deformed the internalchamber structure 110 due to its higher susceptibility to deformation,while leaving the upper and lower cover members 92, 94 in alignment withthe desired planar levels DPL1, DPL2. The drawing of the vacuum on thecavity 100 is contemplated to decrease the internal pressure of thecavity 100 from about 1 atm to less than 10 mbar.

Referring now to FIG. 10A, a cross-sectional view of a vacuum insulatedstructure 90B is shown, wherein the vacuum insulated structure 90Bincludes a number of features that are the same or similar to featuresof the vacuum insulated cabinet 12 shown in FIGS. 1A and 1B, for whichlike reference numerals are used as identifiers. In the cross-sectionalview of FIG. 10A, the vacuum insulated structure 90B includes anexterior wrapper 18 and an upper liner 20A. As noted above, the upperliner 20A includes sidewalls 34, 36 and a rear wall 38 (collectivelyreferred to as sidewalls) which cooperate to define a refrigeratorcompartment 40. The exterior wrapper 18 includes sidewalls 58, 60 and arear wall 62 (collectively referred to as sidewalls) which cooperate todefine outer parameters of the vacuum insulated structure 90B. As notedabove, the exterior wrapper 18 and upper liner 20A are spaced-apart fromone another to define an insulating cavity 24 therebetween. Theinsulating cavity 24 includes a filler such as an insulating mediumidentified above. Particularly, the insulating medium may include apowder having a thermal conductivity of at least 5 mW/m·k or lower.Thus, the vacuum insulated structure 90B represents a cross-sectionalview of a refrigerator compartment, wherein the exterior wrapper 18 andupper liner 20A are interconnected at first and second sides 22A, 22B ofthe thermal bridge 22, also shown in FIG. 1B. Specifically, the exteriorwrapper 18 includes first and second ends 18C, 18D while the upper liner20A includes first and second ends 20C, 20D which are shown connected ina spaced-apart relationship at first and second side members 22A, 22B ofthe thermal bridge 22. As further shown in the embodiment of FIG. 10A, avacuum pump 130 is shown operably coupled to the insulating cavity 24 ofthe vacuum insulated structure 90B to draw a vacuum therefrom. Thevacuum insulated structure 90B of FIG. 10A includes pre-deformations inthe sidewalls 58, 60 and rear wall 62 of the exterior wrapper 18,wherein the pre-deformations extend outwardly beyond a first desiredplanar level DPL1 for the exterior wrapper 18. Similarly, the upperliner 20A includes pre-deformations in the sidewalls 34, 36 and rearwall 38, such that the sidewalls 34, 36 and rear wall 38 of the upperliner 20A include portions which outwardly extend from a second desiredplanar level DPL2 for the vacuum insulated structure 90B. In FIG. 10A,the insulating cavity 24 includes a first interior volume V1.

Referring now to FIG. 10B, it is contemplated that a vacuum has beendrawn on the insulating cavity 24 via vacuum pump 130 such that theforces 132 associated with the vacuum have collapsed thepre-deformations found in the exterior wrapper 18 and upper liner 20A,such that the sidewalls and rear walls thereof are now in-line with thedesired planar levels DPL1, DPL2 indicated in FIG. 10B. In this way, thepre-deformations have provided structural defects that are pulledinwardly due to the forces 132 pulling on the sidewalls and rear wallsof the exterior wrapper 18 and upper liner 20A by the vacuum powergenerated by vacuum pump 130, such that the vacuum insulated structure90B now includes a generally planar structure for the outer surfaces ofthe exterior wrapper 18 and upper liner 20A. The insulating cavity 24shown in FIG. 10B includes a second interior volume V2 that is less thanthe first interior volume V1 (FIG. 10A).

Referring now to FIG. 11A, a vacuum insulated structure 90C is shownhaving exterior wrapper 18 and upper liner 20A interconnected by thethermal bridge 22 in a manner as found in FIGS. 10A and 10B describedabove. In the embodiment shown in FIG. 11A, the vacuum insulatedstructure 90C is shown having the sidewalls 58, 60 and rear wall 62 ofthe exterior wrapper 18 positioned in-line with a first desired planarlevel DPL1. Similarly, the first and second sidewalls 34, 36 and rearwall 38 of the upper liner 20A are also shown positioned at a seconddesired planar level DPL2, such that the vacuum insulated structure 90Cis configured in a pre-vacuum state having the desired parameters forthe vacuum insulated structure 90C already in place. As further shown inFIG. 11A, the insulating cavity 24 has a volume V3 with an insulatingmaterial disposed therein. As further shown in FIG. 11A, internalchamber structures 110A, 110B and 110C are shown disposed within theinsulating cavity 24 at the sidewalls and rear wall of the vacuuminsulated structure 90C. Each one of the internal chamber structures110A-110C includes first and second panels 112, 114 coupled together atperimeter portions 118, 122 thereof to define interior cavities 124having at-rest or pre-vacuumed volumes V1. In a manner similar to thevacuum insulated structure 90A shown in FIGS. 9A and 9B, the walls thatmake up the exterior wrapper 18 and upper liner 20A are considered tohave a deformability factor that is lower than a deformability factor ofthe first and second panels 112, 114 of each of the internal chamberstructures 110A-110C. Thus, as a vacuum is drawn on insulating cavity24, the internal chamber structures 110A-110C are more likely to deformthan the walls of the exterior wrapper 18 and upper liner 20A.

Referring now to FIG. 11B, the vacuum insulated structure 90C is shownand contemplated to have a vacuum drawn on the insulating cavity 24. Asshown in FIG. 11B, the vacuum insulating cavity 24 includes a volume V3that is the same as the volume V3 shown in FIG. 11A. Thus, it iscontemplated that the walls of the exterior wrapper 18 and upper liner20A have remained in-line with the first and second desired planarlevels DPL1, DPL2, respectively, such that the vacuum insulatedstructure 90C has not deformed due to the vacuum being drawn on theinsulating cavity 24. It is contemplated that forces 132 are acting onthe walls of the exterior wrapper 18 and upper liner 20A to pull thewalls inwardly as indicated in FIG. 11B. However, with the deformabilityfactor of the first and second panels 112, 114 of the internal chamberstructures 110A-110C being higher than that of exterior wrapper 18 andupper liner 20A, the internal chamber structures 110A-110C are moresusceptible to deformation than the walls of the exterior wrapper 18 andupper liner 20A, the internal chamber structures 110A, 110C are shown ina deformed state having a volume V2 that is greater than the volume V1shown in FIG. 11A. Thus, it is contemplated as the vacuum is drawn onthe insulating cavity 24, forces 132 are realized on the first andsecond panels 112, 114 to pull the panels 112, 114 apart from oneanother to create a second volume V2 for the internal chamber structures110A-110C. In this way, the internal chamber structures 110A-110C deformas a vacuum is drawn on the insulating cavity 24, while the parameterwalls of the exterior wrapper 18 and upper liner 20A remain intact atthe first and second desired planar levels DPL1, DPL2, respectively,with an unchanged volume V3 for the insulating cavity 24.

Another aspect of the present concept includes a method of making avacuum insulated cabinet structure, such as cabinet structures 12 and90C. The method includes the steps of: 1) providing first and secondpanel members 112, 114; 2) coupling the first and second panel members112, 114 to one another to define an internal chamber structure 110having a sealed interior cavity 124 with a first interior volume V1; 3)providing an exterior wrapper 18 having a receiving cavity 64; 4)positioning at least one liner 20A, 20B in the receiving cavity 64 ofthe exterior wrapper 18; 5) positioning one or more of the internalchamber structures 110A-110C in a space between the exterior wrapper 18and at least one liner 20A, 20B; 6) providing a thermal bridge 22interconnecting the exterior wrapper 18 and the at least one liner 20A,20B to define an insulating cavity 24 therebetween having an interiorvolume V3, the one or more of the internal chamber structures 110A-110Cpositioned within the insulating cavity 24; 7) drawing a vacuum in theinsulating cavity 24; and 8) deforming the one or more internal chamberstructures 110A-110C, such that the interior cavities 124 of the one ormore internal chamber structures 110A-110C outwardly deform to provide asecond interior volume V2 that is greater than the first interior volumeV1.

Another aspect of the present concept includes a method of making avacuum insulated cabinet structure, such as cabinet structures 12 and90B. The method includes the steps of: 1) providing an exterior wrapper18 having a receiving cavity 64 defined by a plurality of sidewalls 54,56, 58, 60, and 62; 2) outwardly deforming one or more of the sidewalls54, 56, 58, 60, and 62 such that the sidewalls 54, 56, 58, 60, and 62include pre-deformations outwardly extending beyond a desired planarlevel DPL1; 3) providing at least one liner 20A having a plurality ofsidewalls 30, 32, 34, 36 and 38 defining a refrigerator compartment 40;4) outwardly deforming one or more of the sidewalls 30, 32, 34, 36 and38 such that the sidewalls 30, 32, 34, 36 and 38 includepre-deformations outwardly extending beyond a desired planar level DPL2;5) positioning the least one liner 20A in the receiving cavity 64 of theexterior wrapper 18; 6) providing a thermal bridge 22 interconnectingthe exterior wrapper 18 and the at least one liner 20A to define aninsulating cavity 24 therebetween having a first interior volume V1; 7)drawing a vacuum in the insulating cavity 24; and 8) collapsing thepre-deformations of the sidewalls 54, 56, 58, 60, and 62 of the exteriorwrapper 18 and the pre-deformations of the sidewalls 30, 32, 34, 36 and38 of the at least one liner 20A to draw the sidewalls 54, 56, 58, 60,and 62 of the exterior wrapper 18 into alignment with the desired planarlevel DPL1 and further draw the sidewalls 30, 32, 34, 36 and 38 of theat least one liner 20A into alignment with the desired planar levelDPL2; and 9) decreasing the first interior volume V1 of the insulatingcavity 24 to a second interior volume V2.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. A method of making a vacuum insulated cabinetstructure, the method including the steps of: providing an exteriorwrapper having a receiving cavity defined by a plurality of sidewalls;outwardly deforming one or more of the sidewalls of the exteriorwrapper, such that the sidewalls of the exterior wrapper includepre-deformations outwardly extending beyond a first desired planarlevel; providing at least one liner having a plurality of sidewallsdefining a compartment; outwardly deforming one or more of the sidewallsof the at least one liner, such that the sidewalls of the at least oneliner include pre-deformations outwardly extending beyond a seconddesired planar level; positioning the least one liner in the receivingcavity of the exterior wrapper; providing a thermal bridgeinterconnecting the exterior wrapper and the at least one liner todefine an insulating cavity therebetween having a first interior volume;drawing a vacuum on the insulating cavity; collapsing thepre-deformations of the sidewalls of the exterior wrapper to draw thesidewalls of the exterior wrapper into alignment with the first desiredplanar level; collapsing the pre-deformations of the sidewalls of the atleast one liner to draw the sidewalls of the at least one liner intoalignment with the second desired planar level; and decreasing the firstinterior volume of the insulating cavity to a second interior volume. 2.The method of claim 1, wherein the sidewalls of the exterior wrapper andthe sidewalls of the at least one liner are comprised of a sheet metalmaterial.
 3. The method of claim 2, wherein the sidewalls of theexterior wrapper and the sidewalls of the at least one liner arepre-deformed in a sheet metal stamping process.
 4. The method of claim3, wherein the stamping process provides weakened portions of thesidewalls of the exterior wrapper and the sidewalls of the at least oneliner.
 5. The method of claim 1, further comprising the step of: sealingthe insulating cavity to maintain the vacuum.
 6. The method of claim 1,wherein the step of drawing the vacuum includes drawing a vacuum of lessthan 10 mbar within the insulting cavity.
 7. The method of claim 1,including the step of: introducing an insulation material into theinsulting cavity.
 8. The method of claim 7, wherein the insulationmaterial includes one of fumed silica, glass beads, processed ricehusks, and a combination thereof.
 9. The method of claim 7, wherein theinsulation material has a thermal conductivity of 5 mW/m·K or lower.